Electrical Discharge Machining of Submicron-Diameter Micropins

Abstract:

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The wire electrodischarge grinding (WEDG), which is one of the electrical discharge machining (EDM) methods, of submicron-diameter zinc micropins was attempted using a relaxation-type pulse generator. Tungsten wire of 30 µm diameter was employed as the tool electrode. The open-circuit voltage was set at lower than or equal to 15 V in the finish machining step. The electrostatic capacitance of the pulse generator was its stray capacitance only. As a result, a micropin of 0.3 µm diameter was processed. They are the smallest-diameter micropins fabricated by EDM, to the best of our knowledge.

Abstract: The mechanism of fracture in micro-electrical discharge machining (-EDM) processes is
related to the discharge pulses energy. This paper investigates the correlation of fractures and
discharge pulses energy in the -EDM of polycrystalline diamond (PCD) to the acoustic emission
(AE) signals. The evaluation of fracture mechanism was done by measuring the generation and
propagation of elastic wave in single discharge pulse by using AE sensor. The results show a strong
correlation between fractures and discharge pulses energy to the AE signals and mechanism of
material removal in the -EDM processes.

Abstract: Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes and controlled process where pulsed electrical discharge is used to erode metal in a workpiece. EDM pulsed power generator applies voltage pulse discharge occurs in a small gap between the work piece and the electrode and removes the unwanted material from the parent metal through melting and vaporization. The essential requirement for EDM system is to obtain the output waveform similar to the ideal EDM waveform. This paper seeks to discuss on the design and simulation based on RC (resistance-capacitance) power generator circuit. Based on the findings of the study, from the equation gained, the simulation is constructed through using electrical model in Matlab Simulink software and circuit analysis in Lapels transform in EDM system process. Also this procedure simulated in Matlab software.

Abstract: There have been few reports on the drilling of microholes on rod end faces by cutting, which can be employed for fabricating micronozzles or microneedles. Such drilling was therefore attempted in the present study using a micro turn-milling machine with the tool and workpiece axes being parallel. The drilling was performed on the end faces of brass rods with cemented tungsten carbide micro-cutting tools processed by electrical discharge machining (EDM). As a result, a microhole 12‍ μm in diameter was successfully drilled using a 10-μm-diameter tool at a feed speed of 0.5‍ μm/s. The feed speed could be increased to 25 μm/s for a tool with a diameter of 20 μm and body length of 50 μm.